Doosan Ingersoll rand xp185wir User manual

ELECTRONIC SERVICE MANUAL

Doosan Infracore Portable Power

P.O. Box 868 - 501 Sanford Ave

Mocksville, N.C. 27028

www.doosanportablepower.com

Book: 23307366 (6/08)

This manual contains important safety information.

Do not destroy this manual.

This manual must be available to the personnel who operate and maintain this machine.

XP185WIR

P260WIR

7/51

7/71

Revised (10-12)

Doosan purchased Bobcat Company from Ingersoll-Rand Company in

2007. Any reference to Ingersoll-Rand Company or use of trademarks,

service marks, logos, or other proprietary identifying marks belonging

to Ingersoll-Rand Company in this manual is historical or nominative

in nature, and is not meant to suggest a current affiliation between

Ingersoll-Rand Company and Doosan Company or the products of

either.

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Book No. 23307366 (06/08)

TABLE OF CONTENTS

SECTION1.......ManualDescription

SECTION2.......GeneralInformationAndOperationalTheory

SECTION3.......ServiceTools

SECTION4.......ElectronicSystemsTroubleshooting

Procedures And Techniques

SECTION5.......SystemSchematicDiagrams

SECTION6.......ElectronicComponent Location Drawings

SECTION7.......IndividualCircuitDiagrams

SECTION8.......ElectricalConnector Information

SECTION9.......ElectricalPartsList

SECTION10......AlertsandShutdownsList

SECTION11......RecommendedSpareParts

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Book No. 23307366 (06/08)

SECTION 1

MANUAL DESCRIPTION

This manual contains all of the information concerning the electrical and electronic systems for

the XP185, P260WIR compressor family. It provides all information necessary to service, trou-

bleshoot and order parts for this machine.

It is organized into 12 sections.

Sections 2 thru 4 cover systems operation and troubleshooting procedures.

Sections 5 thru 7 have location diagrams, drawings of specific circuits and systems schematics.

Section 8 has information concerning the electrical connectors used, including removal and

replacement.

Section 9 contains the parts list with ordering information.

Section 10 contains the list of Alerts and Shutdowns.

Section 11 contains a list of recommended spare parts for servicing.

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Book No. 23307366 (06/08)

SECTION 2

GENERAL INFORMATION

and

OPERATIONAL THEORY

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Book No. 23307366 (06/08)

GENERAL INFORMATION AND OPERATIONAL

THEORY

General

This family of machines has an electronic monitor and

control system to provide discharge air pressure

control and engine and package monitor functions.

The system uses the SECU controller to perform these

functions. The electrical system connects all the

necessary switches, sensors and transducers to the

controller in order for it to perform the monitor and

control functions.

SECU Controller

The controller is the heart of the machine monitor and

control system. It provides data collection, alarming

and control functions for compressor operations. It is a

microcontroller based unit with analog and digital

inputs and outputs.

The controller has a LED display for diagnostics. A

number, 1--9, is shown to indicate a system problem.

The first function of the controller is to scan all analog

and digital inputs at a fixed interval. These inputs are

scanned every 10 milliseconds. The values are then

compared against minimum and maximum values and

an ALERT or SHUTDOWN is issued, if a value is out of

range. The controller will indicate SHUTDOWNS and

ALERTS for compressor system. These are indicated

through fault codes that are displayed on the SECU

LED display.

The second function of the controller is engine speed

control. The controller monitors the regulation system

air pressure and varies the engine throttle to maintain

the setpoint discharge air pressure. The setpoint

pressure is set using the regulator on the separator

tank.

The third function of the controller is to communicate

with the diesel engine controller via the J1939 CAN

network. It retrieves diagnostic information over

J1939.

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Book No. 23307366 (06/08)

FIGURE 2--1

HARNESS SYSTEM SCHEMATIC

SECU

Controller

SOLENOID VALVES

SPEED SENSOR

FUEL LEVEL SWITCH

PRESSURE TRANSDUCERS

TEMPERATURE SENSORS

BATTERY STARTING AND

CHARGING SYSTEM

W1W1

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Book No. 23307366 (06/08)

FIGURE 2--2

SECU

CONTROLLER

SECU TO ENGINE INTERFACE

YANMAR ENGINE

P1--18

P1--17

P1--8

YANMAR

TIER III

ENGINE

CONTROLLER

P2--J1

P2--K1

P2--H4

P2--E3

CAN LO

CAN HI

P1--2

ENGINE START

ENGINE STOP

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Book No. 23307366 (06/08)

J1939 CAN COMMUNICATIONS SCHEMATIC

ENGINE ECM SECU

CONTROLLER

TERMINATOR TERMINATOR

ENGINE DIAGNOSTICS JACK

J10

TR2P9 TR1

FIGURE 2--3

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Book No. 23307366 (06/08)

Figure 2--2 shows the signals between the engine

controller and the SECU controller.

Sensors and Transducers

The electronics system contains sensors and trans-

ducers that are used to collect data from the compres-

sor. The temperature is measured by a thermistor.

This device exhibits a change in resistance as the tem-

perature changes. The resistance change causes an

input voltage change to the controller input and is inter-

preted as a temperature change.

The electronics system also uses pressure transduc-

ers to measure compressor pressure changes. These

devices have an output signal of 0.5 VDC to 4.5 VDC,

corresponding to 0 psi and the maximum measured

psi for a particular device. The maximum pressure

transducer range is 100 psi. The transducer is pro-

vided with 5 VDC excitation to power the device. It is a

three wire device: excitation, signal and ground.

Digital Inputs and Outputs

The controller scans digital inputs such as switch

contacts. These are either “ON” (12VDC) or “OFF” (0

VDC). These digital inputs are connected to switches

within the package such as the key start switch and air

filter switches.

The controller provides 12 VDC digital outputs to

control solenoids. These are 12 VDC “ON” and 0 VDC

“OFF”. They are current limited and short circuit

protected.

Controller Outputs

The controller has outputs to activate relays, hourmet-

er, fuel lift pump and starter solenoid.

Engine speed control is performed by a command sent

over the J1930 CAN Network from the SECU to the

Engine Control Module.

Pressure Control

The discharge pressure is controlled by manipulating

the engine speed and compressor inlet valve position.

The inlet valve position is controlled pneumatically and

the engine speed is determined by the controller.

The controller measures the pneumatic system regu-

lation pressure and computes an engine throttle set-

ting. This throttle setting is sent to the engine via the

J1939 throttle.

J1939 Data Link

The CAN network is a single twisted pair cable located

with the W1 main harness. Figure 2--3 shows a layout

of the CAN harness or “backbone” as it is referred to.

The termination resistors (Terminator) are important to

prevent reflections on the transmission line and must

be in place for the network to function properly.

The engine diagnostics connector is located on the left

side of the engine. This is used to connect the engine

manufacturer’s service tools to the CAN network. This

connector also provides 12 VDC to power these

service tools.

Electrical System

The schematic diagrams show the wiring harness con-

nections. Figure 2--1 is a system schematic showing

harness connection with devices and controllers. Sec-

tion 8 includes information on connectors used in the

harness.

The electrical circuits are protected using ATC style

fuses. A fuse should only be replaced with one of the

same rating. Replacing a fuse with one of a large

rating could lead to harness damage. If a fault occurs

and the circuit does not have the appropriate size fuse,

wires could be burned in the harness and damage

other circuits.

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Book No. 23307366 (06/08)

KEY ELECTRICAL COMPONENTS FUNCTION

PS--1:

PS--1 is a 0--100 psi gauge pressure transducer that measures regulation system pressure.

U1:

U1 is resistive level detector that measures the fuel level in the fuel tank.

It provides a continuous reading of fuel level. It also has a switch for low fuel level and low fuel shutdown.

K1:

K1 is SPST, 12VDC relay used to activate the engine starter.

K2:

K2 is a SPST, 12VDC relay used to activate the engine inlet heater.

K3:

Provides Power to the Engine Control Module.

K4:

Is the fuel rack acutator relay for the engine.

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Book No. 23307366 (06/08)

OPERATIONAL INFORMATION

XP185/P260 Family

Power “ON” at Control Panel:

1. Key switch signal (12VDC) supplied relay to engine ECU.

Engine Start--up:

When the key is switched to the engine crank position:

1. K1 auxiliary start relay is engaged.

When the engine speed reaches 600 RPM (engine start declared):

Loading:

When the “Service Air” switch (if available) is pushed:

1. The SECU sets engine speed (varies with unit)

After 2 seconds and the regulation system pressure is 4 psi or greater:

1. The SECU initiates compressor pressure control via engine speed control.

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Book No. 23307366 (06/08)

SECTION 3

SERVICE TOOLS

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Book No. 23307366 (06/08)

SERVICE TOOLS

Service Tools

The following special tools are recommended to perform service procedures in this manual. The tools can

be purchased from Ingersoll Rand or other sources as listed.

Tool Tool Description

22216691 Digital Multimeter (Fluke 87)

Used to measure electrical circuits; Volts, amps, ohms

54729660 Packard Weather--Pack Terminal Removal Tool

Used to repair Packard Electric Weather--Pack Connectors

54699632 Deutsch Terminal Removal Tool (Blue)